Process for the preparation of magadiite from an organic structuring agent of quaternary diammonium type

ABSTRACT

Described is a process for the preparation of a crystallised lamellar solid formed by magadiite consisting of implementing in a step (i) mixing of at least one silica source, at least one salt of N,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium, at least one alkali and/or alkaline earth metal M and water and then implementing in a step (ii) hydrothermal treatment of said mixture until said crystallised lamellar solid constituted by magadiite is formed.

FIELD OF THE INVENTION

The invention concerns the field of the preparation of solids formed bymagadiite. These involve silicate-based lamellar solids also known bythe name of lamellar solids of phyllosilicates or lamellar silicatestype. The expression silicate-based lamellar solid is used to denote asolid compound formed by layers (or sheets) which are superposed butseparated from each other by a distance varying between 2 and 5 Å, saidsheets being formed by silica arranged in tetrahedric co-ordination(SiO₄). Elements other than silicon Si can be present in the solid, alsoin the tetrahedric position.

PRIOR ART

Among lamellar silicates, mention may be made of magadiite, natrosilite,kenyaite, makatite, nekoite, kanemite, okenite, dehayelite, macdonaliteand rhodesite.

Those solids often exist in the natural state with a composition of thetype A_(x)Si_(y)O_(z), nH₂O, with 1≦x≦15, 2≦y≦32, 4≦x≦80 and 0≦n≦20 (x,y, z and n being rational numbers or integers), and A can be for examplean element sodium or potassium. Such lamellar solids involve for examplethe composition Na₂Si₁₄O₂₉.9H₂O for magadiite and the compositionNa₂Si₂₀O₄₁. 10H₂O for kenyaite. The solids obtained by synthesis are ofthe same composition as the solids which are present in the naturalstate. Those lamellar silicates, in particular magadiite, often involvea three-dimensional structure with interactions of Van der Walls typebetween the sheets and a small specific surface area.

Those lamellar silicates and in particular magadiite have absorption andexchange properties which are of interest. Those solids are particularlysuited for the adsorption of water or organic molecules and for cationicsurface exchange. Recently, lamellar silicates have been widely studiedin relation to their capacity to become an acid solid by protonicexchange. Other studies have also demonstrated that the introduction ofpillars into the interlamellar spaces makes it possible to create amesoporosity and to increase the specific surface area.

It is known from patent application WO 88/00091 to synthesise a bridgedlamellar silicate from a lamellar silicate formed by synthesis magadiitewhich was prepared using an organic structuring agent which is selectedfrom benzyltriethylammonium chloride, benzyltrimethylammonium chloride,dibenzyldimethylammonium chloride, N,N′-dimethylpiperazine,triethylamine or other quaternary compounds or heterocyclic amines.

It is also known from patent application WO 91/12204 to synthesise acrystallised lamellar silicate of kenyaite type using an organiccompound selected from an alkylamine, a trialkylamine, atetraalkylammonium compound and a diamine trimethylhexamethylenediamine,said alkyl having from 1 to 12 carbon atoms.

It is known from patent application EP-A-1 559 681 to synthesiselamellar solids based on silicates of kenyaite and magadiite type usingan organic structuring agent selected from tyramine, 4-aminophenol,trans-4-aminocyclohexanol, 2-(4-amino-phenyl)-ethanol or other compoundscomprising at least one alcohol group and at least one amine group whichare separated by a hydrocarbon chain having from 1 to 20 carbon atoms.

BRIEF DESCRIPTION OF THE INVENTION

The invention concerns a process for the preparation of a crystallisedlamellar solid formed by magadiite consisting of implementing in a step(i) mixing of at least one silica source, at least one salt ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium, at least one alkaliand/or alkaline earth metal M and water and then implementing in a step(ii) hydrothermal treatment of said mixture until said crystallisedlamellar solid constituted by magadiite is formed. Advantageously saidmixture formed in the course of said step (i) comprises at least onesource of at least one element X involving tetrahedric coordinance anddiffering from silicon.

It was discovered that, surprisingly, a nitrode-bearing organicstructuring agent comprising two quaternary ammonium functions separatedby the unit of a methylene chain—(CH₂)— repeated 8 times, a salt ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium, mixed with a silicasource, at least one alkali and/or alkaline earth metal and water, leadsto the production of a high-purity magadiite. The process according tothe invention most often leads to a pure magadiite, in the absence ofany other crystallised or amorphous phase. The magadiite obtained withthe process of the invention is produced with a better degree ofselectivity than the solids formed by magadiite which are obtained inaccordance with the processes in the state of the art. In addition sucha magadiite prepared by the process of the invention is obtained withvery good crystallinity. Purity and selectivity are determined by X-raydiffraction.

DETAILED DESCRIPTION OF THE INVENTION

The invention concerns a process for the preparation of a crystallisedlamellar solid formed by magadiite consisting of implementing in a step(i) mixing of at least one silica source, at least one salt ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium, at least one alkaliand/or alkaline earth metal M and water and then implementing in a step(ii) hydrothermal treatment of said mixture until said crystallisedlamellar solid constituted by magadiite is formed.

The salt of N,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium which isincorporated in step (i) of the preparation process of the invention ispreferably a N,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammoniumdihalide and very preferably aN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium dibromide. That saltis synthesised by any method known to the man skilled in the art. If itis a N,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium dihalide, theprocess involves mixing one mole of dihalogenooctane and at least 2moles of N-benzyldimethylamine. For the synthesis ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium dibromide, theprocess involves mixing one mole of 1,8-dibromooctane and at least 2moles of N-benzyldimethylamine.

The alkali and/or alkaline earth metal M incorporated in step (i) of thepreparation process according to the invention is selected from lithium,potassium, sodium and calcium and a mixture of at least two of thosemetals. Preferably said metal M is an alkali metal and very preferablyit is sodium.

The silica source incorporated in step (i) of the preparation processaccording to the invention can be any one of those currently used in thesynthesis of crystallised lamellar solids based on silicates, forexample silica in powder form, silicic acid, colloidal silica, dissolvedsilica or tetraethoxysilane (TEOS). Among the silicas in powder form, itis possible to use precipitated silicas, in particular those obtained byprecipitation from a solution of silicate of alkali metal such aspyrogenated silicas, for example “CAB-O-SIL” and silica gels. It ispossible to use colloidal silicas involving different particle sizes,for example of a mean equivalent diameter of between 10 and 15 nm orbetween 40 and 50 nm, such as those commercialised under the registeredmarks such as “LUDOX”. Preferably the silicon source is LUDOX.

In accordance with the process for the preparation of a crystallisedlamellar solid according to the invention, the mixture formed in thecourse of the step (i) advantageously comprises at least one source ofat least one element X involving tetrahedric coordinance and differingfrom silicon. More preferably the element X is selected from the groupformed by aluminium, boron, chromium, iron, gallium, indium, nickel,zirconium, cobalt, titanium, zinc, copper, niobium and europium and amixture of at least two of those elements. Still more preferably theelement X is aluminium. The source of the element X may be any compoundcomprising the element X and capable of liberating that element inaqueous solution in reactive form. The element X can be incorporatedinto the mixture in an oxidated form XO_(n) with 1≦n≦3 (n being arational number or an integer), or in any other form such as for examplea diacetate of the element X, in particular Co(CH₃COO)₂, Ni(CH₃COO)₂,Zn(CH₃COO)₂, Cu(CH₃COO)₂, Cr(CH₃COO)₂ and Eu(CH₃COO)₂. When X istitanium, Ti(EtO)₄ is advantageously used, when X is zirconium, Zr(OH)₄is advantageously used, and when X is niobium Nb₂B₄O₇ or Nb₂O₅ isadvantageously used. In the preferred case where X is aluminium thealumina source is preferably sodium aluminate or an aluminium salt, forexample chloride, nitrate, hydroxide or sulphate, an aluminium alkoxideor alumina in the true sense, preferably in hydrated or hydratable form,such as for example colloidal alumina, pseudoboehmite, gamma alumina oralpha or beta trihydrate. It is also possible to use mixtures of theabove-mentioned sources.

In accordance with the preparation process according to the inventionthe reaction mixture obtained in step (i) is of a chemical compositionexpressed in terms of moles of oxides by the following formula:

SiO₂:wXO_(n):x^(M+)OH³¹:yH₂O:zRO

-   -   w being between 0 and 0.5, preferably between 0 and 0.1, very        preferably between 0.001 and 0.1,    -   x being between 0.001 and 1, preferably between 0.01 and 0.6,    -   y being between 10 and 100,    -   z being between 0.01 and 3, preferably between 0.05 and 1, and    -   n being between 1 and 3,        and in which X is at least one element involving tetrahedric        coordinance and differing from silicon, preferably selected from        the group formed by aluminium, boron, chromium, iron, gallium,        indium, nickel, zirconium, cobalt, titanium, zinc, copper,        niobium and europium and the mixture of at least two of those        elements, still more preferably X is aluminium, M is at least        one cation selected from lithium, potassium, sodium and calcium        and a mixture of at least two of those metals, preferably        sodium, R is        N,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium. w, x, y and        z respectively represent the number of moles of XO_(n), M⁺OH⁻,        H₂O and RO.

In accordance with step (ii) of the process of the invention thehydrothermal treatment of the reaction mixture is effected until saidcrystallised lamellar solid constituted by magadiite is formed. Thereaction mixture is advantageously put under hydrothermal conditionsunder an autogenous reaction pressure, possibly with the addition ofgas, for example nitrogen, at a crystallisation temperature of between100 and 200° C., preferably between 110° C. and 170° C., until formationof the lamellar crystals of magadiite occurs. The period of timenecessary to achieve crystallisation generally varies between 1 and 50days, preferably between 3 and 21 days and more preferably between 5 and10 days. During the duration of crystallisation step (ii) the reactionmixture can be vigorously agitated or may not be. The operatingconditions for the crystallisation operation are selected by the manskilled in the art to obtain pure magadiite, in the absence of any othercrystallised or amorphouse phase. The preparation process according tothe invention is thus highly selective as it results in pure magadiiteunder the above-indicated crystallisation operating conditions.

Preferably the product obtained at the end of the crystallisation step(ii) is subjected to at least one of the following steps and preferablyall of the following steps:

(iii) a step for separation of the crystallised lamellar solid from thecrystallisation mixture,

(iv) a step of washing the crystallised lamellar solid, and

(v) a step of drying the crystallised solid.

The crystallised solid is generally separated from the mixture inaccordance with step iii) of the preparation process according to theinvention by any method known to the man skilled in the art such asfiltration. The solid is then washed with water in accordance with stepiv) of the process of the invention, preferably using deionised water.Step v) is generally carried out at a temperature of between 50 and 150°C. for a period ranging from 12 to 30 hours. The drying operation ispreferably effected at atmospheric pressure but it may also be carriedout under pressure. At the end of all those steps the result obtained isa crystallised lamellar solid formed by magadiite.

In accordance with the invention it is advantageous to carry out acationic exchange operation in respect of the alkali and/or alkalineearth metal introduced in the course of said step i) of the process forthe preparation of said crystallised lamellar solid, said cationicexchange being carried out with hydrogen ions at the end of step v) fordrying said lamellar solid. That cationic exchange with protons impartsacidity to the crystallised lamellar solid formed by magadiite.

The following examples illustrate the invention without limiting thescope thereof.

EXAMPLE 1 Synthesis ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium dibromide

50 g of 1,8-dibromooctane (0.18 mole, 99%, Aldrich) is added in a 500 mlballoon flask containing 150 ml of ethanol and 62 g ofN-benzyldimethylamine (0.46 mole, 99% Aldrich). The reaction mixture isagitated and put under reflux for a period of 10 h. The mixture is thencooled to ambient temperature, poured into 300 ml of diethylether andthen filtered and washed with 100 ml of diethylether. The solid obtainedis dried under vacuum for a period of 12 h. The result obtained is 97 gof a white solid (that is to say, a yield of 97%).

The product has the expected ¹H NMR spectrum. ¹H NMR (D₂O, ppm/TMS):1.23 (8H, m); 1.71 (4H, m); 2.85 (12H, s); 3.10 (4H, m); 4.31 (4H, s);7.40 (10H, m).

EXAMPLE 2 Synthesis of Silicic Magadiite

13.8 g of a colloidal silica suspension known by the commercial nameLudox HS-40 and marketed by Aldrich is incorporated into a solutioncomposed of 1.25 g of sodium hydroxide (prolabo), 8.31 g ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium dibromide in 46.63 gof deionised water. The mixture is vigorously agitated for half an hour.The mixture is then transferred, after homogenisation, into anautoclave. The autoclave is heated for a period of 5 days at 130° C. inan oven without agitation. The crystallised product obtained isfiltered, washed with deionised water (to reach a neutral pH) and thendried for one night at 100° C.

The diffractogram (DRX) carried out on that product is characteristic ofpure magadiite.

EXAMPLE 3 Synthesis of Magadiite Substituted with Aluminium

13.8 g of a colloidal silica suspension known by the commercial nameLudox HS-40 and marketed by Aldrich is incorporated into a solutioncomposed of 0.084 g of sodium aluminate (Carlo Erba), 1.22 g of sodiumhydroxide (prolabo), 8.31 g ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium dibromide in 46.60 gof deionised water. The mixture is vigorously agitated for half an hour.The gel formed in that way has an Si/Al ratio of 120. The mixture isthen transferred, after homogenisation, into an autoclave. The autoclaveis heated for a period of 7 days at 130° C. in an oven withoutagitation. The crystallised product obtained is filtered, washed withdeionised water (to reach a neutral pH) and then dried for one night at100° C.

The diffractogram (DRX) carried out on that product is characteristic ofpure magadiite.

EXAMPLE 4 Synthesis of Magadiite Substituted with Aluminium

13.8 g of a colloidal silica suspension known by the commercial nameLudox HS-40 and marketed by Aldrich is incorporated into a solutioncomposed of 0.034 g of sodium aluminate (Carlo Erba), 1.24 g of sodiumhydroxide (prolabo), 8.31 g ofN,N,N′,N′-tetramethyl-N,N′-dibenzyloctanediammonium dibromide in 46.63 gof deionised water. The mixture is vigorously agitated for half an hour.The gel formed in that way has an Si/Al ratio of 300. The mixture isthen transferred, after homogenisation, into an autoclave. The autoclaveis heated for a period of 7 days at 130° C. in an oven withoutagitation. The crystallised product obtained is filtered, washed withdeionised water (to reach a neutral pH) and then dried for one night at100° C.

The diffractogram (DRX) carried out on that product is characteristic ofpure magadiite.

EXAMPLE 5 (Not According to the Invention): Synthesis ofN,N,N′,N′-tetramethyl-N,N′-dibenzylbutanediammonium dibromide

50 g of 1,4-dibromobutane (0.23 mole, 99% Aldrich) is added in a 500 mlballoon flask containing 150 ml of ethanol and 72 g ofN-benzyldimethylamine (0.53 mole, 99% Aldrich). The reaction mixture isagitated and put under reflux for a period of 10 h. The mixture is thencooled to ambient temperature, poured into 300 ml of diethylether andthen filtered and washed with 100 ml of diethylether. The solid obtainedis dried under vacuum for a period of 12 h. The result obtained is 105 gof a white solid (that is to say, a yield of 94%).

The product has the expected ¹H NMR spectrum. ¹H NMR (D₂O, ppm/TMS):1.79 (4H, m); 2.88 (12H, s); 3.23 (4H, m); 4.34 (4H, s); 7.49 (10H, m).

EXAMPLE 6 (Not According to the Invention): Hydrothermal Synthesis inthe Presence of N,N,N′,N′-tetramethyl-N,N′-dibenzylbutanediammoniumdibromide as a Structuring Agent

13.9 g of a colloidal silica suspension known by the commercial nameLudox HS-40 and marketed by Aldrich is incorporated into a solutioncomposed of 0.344 g of sodium aluminate (Carlo Erba), 1.11 g of sodiumhydroxide (prolabo), and 7.53 g ofN,N,N′,N′-tetramethyl-N,N′-dibenzylbutanediammonium in 47.07 g ofdeionised water. The mixture is vigorously agitated for half an hour.The mixture is then transferred, after homogenisation, into anautoclave. The autoclave is heated for a period of 7 days at 130° C. inan oven without agitation. The product obtained is filtered, washed withdeionised water (to reach a neutral pH) and then dried for one night at100° C.

Analysis by X-ray diffraction shows that the solid formed is constitutedonly by amorphous phases.

EXAMPLE 7 (Not According to the Invention): Hydrothermal Synthesis inthe Presence of N,N,N′,N′-tetramethyl-N,N′-dibenzylbutanediammoniumdibromide as a Structuring Agent

14.0 g of a colloidal silica suspension known by the commercial nameLudox HS-40 and marketed by Aldrich is incorporated into a solutioncomposed of 1.25 g of sodium hydroxide (prolabo) and 7.54 g ofN,N,N′,N′-tetramethyl-N,N′-dibenzylbutanediammonium in 47.25 g ofdeionised water. The mixture is vigorously agitated for half an hour.The mixture is then transferred, after homogenisation, into anautoclave. The autoclave is heated for a period of 14 days at 130° C. inan oven without agitation. The product obtained is filtered, washed withdeionised water (to reach a neutral pH) and then dried for one night at100° C.

Analysis by X-ray diffraction shows that the solid formed is constitutedonly by amorphous phases and zeolite ZSM-12.

EXAMPLE 8 (Not According to the Invention): Hydrothermal Synthesis inthe Presence of N,N,N′,N′-tetramethyl-N,N′-dibenzylbutanediammoniumdibromide as a Structuring Agent

14.0 g of a colloidal silica suspension known by the commercial nameLudox HS-40 and marketed by Aldrich is incorporated into a solutioncomposed of 1.26 g of sodium hydroxide (prolabo) and 7.54 g ofN,N,N′,N′-tetramethyl-N,N′-dibenzylbutanediammonium in 47.22 g ofdeionised water. The mixture is vigorously agitated for half an hour.The mixture is then transferred, after homogenisation, into anautoclave. The autoclave is heated for a period of 7 days at 170° C. inan oven without agitation. The product obtained is filtered, washed withdeionised water (to reach a neutral pH) and then dried for one night at100° C.

Analysis by X-ray diffraction shows that the solid formed is constitutedonly by dense phases such as quartz and cristobalite and zeolite ZSM-12.

EXAMPLE 9 (Not According to the Invention in Accordance with WO88/00091): Synthesis of Magadiite Substituted with Aluminium in thePresence of Dibenzyldimethylammonium Chloride as a Structuring Agent

24.5 g of dibenzyldimethylammonium chloride is added to a solutioncontaining 0.63 g of sodium aluminate, 4.0 g of sodium hydroxide and30.0 g of deionised water. The mixture is added to 134.0 g of colloidalsilica and then mixed. The mixture is heated at 140° C. in an staticreactor for a period of 21 days.

Analysis by X-ray diffraction indicates that the product obtained isformed by magadiite and a trace of mordenite.

Without further elaboration, it is believed that one skilled in the artcan, using the preceding description, utilize the present invention toits fullest extent. The preceding preferred specific embodiments are,therefore, to be construed as merely illustrative, and not limitative ofthe remainder of the disclosure in any way whatsoever.

In the foregoing and in the examples, all temperatures are set forthuncorrected in degrees Celsius and, all parts and percentages are byweight, unless otherwise indicated.

The preceding examples can be repeated with similar success bysubstituting the generically or specifically described reactants and/oroperating conditions of this invention for those used in the precedingexamples.

The entire disclosures of all applications, patents and publications,cited herein and of corresponding French application No. 06/10.998,filed Dec. 15, 2006 are incorporated by reference herein.

From the foregoing description, one skilled in the art can easilyascertain the essential characteristics of this invention and, withoutdeparting from the spirit and scope thereof, can make various changesand modifications of the invention to adapt it to various usages andconditions.

1. A process for the preparation of at least one crystallised lamellarsolid selected from magadiite and kenyaite comprising implementing in astep (i) mixing of at least one silica source, at least one organicstructuring agent of the formula HO—(CH₂)_(n)—OH, with 2≦n≦5, at leastone alkali and/or alkaline earth metal M and water and then implementingin a step (ii) hydrothermal treatment of said mixture until at leastsaid crystallised lamellar solid is formed.
 2. A preparation processaccording to claim 1 wherein said organic structuring agent comprisingethylene glycol, butane-1,4-diol or pentane-1,5-diol.
 3. A preparationprocess according to claim 2 wherein said organic structuring agentcomprising ethylene glycol.
 4. A preparation process according to claim1 wherein said alkali and/or alkaline earth metal M comprising fromlithium, potassium, sodium or calcium or a mixture of at least two ofthose said metals.
 5. A preparation process according to claim 4 whereinsaid alkali and/or alkaline earth metal M comprising sodium.
 6. Apreparation process according to claim 1 wherein said silica source isincorporated in said step (i) comprising a colloidal silica.
 7. Apreparation process according to claim 1 wherein said mixture formed inthe course of said step (i) comprises at least one source of at leastone element X involving tetrahedric coordinance and differing fromsilicon.
 8. A preparation process according to claim 7 wherein saidelement X is aluminium.
 9. A preparation process wherein the resultantreaction mixture obtained in said step (i) is of a chemical compositionexpressed in terms of moles of oxides by the following formula:SiO₂:wXO_(a):xM⁺OH⁻:yH₂O:zR w being between 0 and 0.5, x being between0.001 and 1, y being between 10 and 100, z being between 0.05 and 15, abeing between 1 and 3, and in which X is at least one element oftetrahedric coordinance and differing from silicon, M is at least onecation selected from lithium, potassium, sodium and calcium and amixture of at least two of those metals, R the organic structuring agentof the formula HO—(CH₂)_(n)—OH, 2≦n≦5, w, x, y and z respectivelyrepresenting the number of moles of XO_(a), M⁺OH⁻, H₂O and R.
 10. Apreparation process according to claim 1 wherein said step (ii) iscarried out by subjecting said reaction mixture to hydrothermalconditions under an autogenous reaction pressure at a crystallisationtemperature of between 100 and 200° C.
 11. A preparation processaccording to claim 1 wherein said hydrothermal treatment in step (ii) isconducted for 10-48 hours.
 12. A preparation process according to claim1 further comprising said product resulting from said crystallisationstep (ii) subjected subjecting to at least: (iii) a step for separationof at least said crystallised lamellar solid from the crystallisationmixture, (iv) a step of washing at least said crystallised lamellarsolid, and (v) a step of drying at least said crystallised solid.
 13. Apreparation process according to claim 3 wherein said alkali and/oralkaline earth metal M comprising sodium.
 14. A preparation processaccording to claim 13 wherein said silica source is incorporated in saidstep (i) comprising a colloidal silica.
 15. A preparation processaccording to claim 14 further comprising admixing aluminum in step (i).